# Patent

## Title
Method and apparatus for control of cooling system air quality and energy consumption

## Abstract

An energy saving air quality control system modulates supply fan speed by use of controlled, variable-frequency drive controls for automatic dampers or suction pressure to maintain adequate air flow across the evaporator coil at partial cooling loads. Indexing the fan speed to maintain the suction pressure of the energized coil controls the maximum relative humidity of the conditioned space. Demand ventilation in the system balances air quality and energy consumption by controlling the outdoor air damper in response to indoor CO2 and humidity levels. The control system variously either (1) produces a variable 0-10 VDC output signal to modulate the outside ventilation air damper as required to keep the CO2 and humidity concentration below a set point; (2) produces a 0 or 24 VAC signal to either open or close a two-position outside air damper for as long a time period as is required in order to keep the CO2 concentration and humidity below a set point; or (3) allows manually setting the outside air damper to provide proper ventilation air at maximum occupancy and maximum air flow and modulates the supply fan speed as required to keep the CO2 concentration and humidity level as measured by a CO2 monitor and leaving air dewpoint temperature below set point.

## Background
FIELD OF THE INVENTION
This application is a continuation-in-part of application Ser. No. 12/214,085, filed Jun. 17, 2008 now U.S. Pat. No. 7,918,407. The present invention pertains to a control system for varying the speed of a fan drive motor for a forced air indoor space heating/cooling system during all modes of operation of the heating/cooling system.


BACKGROUND OF THE INVENTION
Single-zone rooftop units have been used worldwide for the last 40 years on small office buildings, shopping malls, and retail stores. Single-zone air conditioning units have long been the lowest first-cost method of air conditioning buildings. The operating cost (energy use) of the systems has not been a significant consideration until recently, with the current focus on energy consumption and its link to both global warming and increased costs.
As air conditioning units go, single-zone package units have been considered to be a commodity item and, as such, they have limited sophistication when it comes to energy saving features. Current state-of-the-art air conditioning units are becoming more energy efficient by using variable airflow, improved heat transfer surfaces, more efficient fans, and more efficient compressors, but no retrofit exists for the literally millions of existing air conditioning units that could operate with less energy without sacrificing comfort. A retrofit is needed that may be applied to any brand of rooftop unit with gas, electric, or reverse cycle (heat pump) heat and is also compatible with single-zone split heating, ventilation, and air conditioning (HVAC) systems.
SUMMARY OF THE INVENTION
The present invention provides a fan or blower drive motor control system for a forced air heating/cooling system wherein a control circuit is provided that varies the speed of the fan drive motor during all modes of the heating/cooling system's operation. The control system may be easily adapted to retrofit conventional heating/cooling system controls to vary the forced air fan or blower drive motor speed in response to all operation modes of the system as well as the humidity and CO2 levels sensed within the air flow circuit. The control system is particularly adapted for but not limited to use with rooftop heating/cooling systems and is also compatible with single-zone split heating, ventilation, and air conditioning (HVAC) systems.
The control system includes a power supply and a control for the drive motor speed. The control system also includes circuits for detecting temperature and CO2 concentration levels and a circuit that provides for driving motor speed in response to the levels detected.
The control system of the present invention advantageously reduces energy consumption of conventional forced air heating and cooling systems, hot and cold air drafts, noise associated with fan or blower operation, and indoor humidity and CO2 levels.
Those skilled in the art will further appreciate the important features and advantages of the invention upon reading the detailed description of the preferred embodiments hereof that follows with reference to the accompanying drawings.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of the Affinity Laws governing air flow mechanics.
FIG. 2 is a chart showing the relationship between airflow reduction and horsepower reduction.
FIG. 3 is an illustration of hot gas bypass of the prior art.
FIG. 4 is an illustration of DX coils that are face-split circuited.
FIG. 5 is an illustration of DX coils that are interlaced circuited.
FIG. 6 is an illustration of a single zone rooftop forced air heating/cooling unit with face-split coils, a variable frequency drive, face damper, temperature and CO2 sensors, and demand ventilation according to the third option discussed herein for use with either the first or the second preferred embodiments of the instant invention.
FIG. 7 is a psychrometric chart showing the temperatures of the mixed air entering and leaving a cooling coil pursuant to air handling by the system of the present invention.
FIGS. 8-12 are graphs showing percent of total airflow at each outlet for each fan speed using the present invention, compared to maximum airflow.
FIG. 13 is a chart summarizing the results of graphs presented in FIGS. 8-12.
FIG. 14 is a wiring diagram for the present invention with either face-split coils or interlaced coils and demand ventilation for use with an existing thermostat or control system.
FIG. 15 is a wiring diagram for the present invention with either face-split or interlaced coils and demand ventilation for use with a room temperature and optional relative humidity sensor.



DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In the description that follows, like elements are marked throughout the specification and the drawings with the same reference numerals.
Detailed Description
The purpose of the control system of the present invention is to provide an energy-conserving retrofit for existing rooftop forced air heating/cooling systems to vary the speed of the fan drive motor during all modes of the heating/cooling system's operation. The present invention may be installed in a rooftop forced air heating/cooling system with no modification to either the existing thermostat and temperature control system, or more importantly, the internal refrigerant system.
One of the energy-saving features of the present invention is that it changes the speed of the supply fan based on the operating mode of the unit. There are typically a maximum of five operating modes of a commercial single zone rooftop air conditioning unit. The modes are deadband, when only the unit supplier fan is running; first and second stage cooling; and first and second stage heating. Depending on the capacity of the rooftop unit, the number of cooling and heating stages may vary. The controller of the present invention has several embodiments, and each may be programmed to match the specific unit it will control.
The scientific principles underlying the function of the present invention are expressed in the Affinity Laws. Referring to FIG. 1, the Affinity Laws provide that the horsepower varies as the cube of the ratio of the airflows. This relationship results in significant supply fan energy savings when utilized by the controller of the present invention. Since motor power is a function of shaft load, and shaft load is a function of flow and pressure, reducing flow can reduce power usage significantly. Referring now to FIG. 2, and applying the Affinity Laws, the horsepower can be reduced by 27.1% at 10% airflow reduction to 93.6% at 40% airflow reduction.
There is a sound technical basis for varying the airflow being delivered to the occupied space as the operating mode changes. During the occupied mode, an air conditioning/heating unit-operating mode varies as the cooling and heating loads change. The load changes are caused by variations in weather, number of people, and internal load factors such as lighting, computers, and the like in the conditioned space. Typically the volume of airflow delivered to the occupied space is calculated assuming the outdoor weather condition is the warmest and most humid day of the year, and that at the same time, the maximum number of people are in the occupied space, and that the maximum number of lights and other internal loads are on.
In reality, the likelihood that all of the previously mentioned conditions would actually occur simultaneously is either small (5% of the time or less) or non-existent. The required maximum airflow for cooling is calculated using the following equation:

Fan cfm=Q/1.08×(t1−t2)

    
    
        Fan cfm is the cubic feet per minute of conditioned air delivered to the conditioned space by the supply fan.
        Q=The total room sensible heat (heat from building ceiling, wall, floor, glass transmission, people, lights, and other internal sensible heat sources measured in Btu's (British thermal units) per hour. Sensible heat is defined as the heat absorbed or evolved by a substance during a change of temperature that is not accompanied by a change of state.
        1.08=a constant that is based on the properties of air.
        t1=the required space design dry bulb temperature.
        t2=the dry bulb temperature leaving the cooling coil in the rooftop forced air heating/cooling system.
    
    


In normal comfort cooling applications, the cooling cfm is much larger than the heat cfm, so the cooling cfm is selected for the design rooftop unit airflow exercise here.
Based on the equation, if the room's sensible heat drops, the airflow will drop proportionally, i.e., a 50% drop in the room sensible heat requires only 50% of the airflow capacity. While most of the current state-of-the-art air conditioning systems used in upscale office buildings vary the airflow to match the varying load, the single-zone rooftop equipment that has been used for years on most small office buildings, shopping malls, and retail stores delivers the maximum airflow to the conditioned space anytime the space is occupied during business hours. This not only uses more electrical energy to run the fan, but it also tends to have an undesirable effect on comfort and indoor relative humidity. When the rooftop unit is in the heating or deadband mode, maximum airflow delivery to the conditioned space often feels uncomfortably drafty to the occupants.
Retrofits that reduce the airflow on single-zone rooftop forced air heating/cooling systems in the heating and deadband (sometimes referred to as “ventilation”) modes have been used with some success in some retail facilities in the past.
However, there are several distinct differences between the present invention and designs of the prior art. One difference between these previous designs and the present invention is that the present invention varies the airflow in the cooling mode as well as in the heating and deadband modes. In most small offices, retail stores, and shopping malls, the great majority of operating hours, and therefore the most energy saving opportunities, are during the cooling mode. The reason that most of the operating hours are in the cooling mode is that the internal heat gains typically more than offset the building transmission losses even in cool weather, thus cooling is required.
The reason variable airflow has not been used successfully in the cooling mode in the past is that typical single-zone rooftop units, which use direct expansion (DX) cooling coils, can have operational problems if the airflow is varied at partial cooling loads without taking the proper precautions to protect the refrigeration components. The problem is that low refrigerant operating pressure can cause nuisance safety trip-outs, coil icing, and in some cases, compressor damage through refrigerant liquid slugging and compressor short-cycling.
Referring now to FIG. 3, in applications where variable airflow in rooftop air conditioning units is required, as in terminal variable air volume systems, the industry practice has been to employ discharge air temperature control in conjunction with refrigerant hot gas bypass. The discharge air temperature is used to stage compressors so that a reasonably constant discharge air temperature is maintained. The supply fan is modulated with a variable frequency drive to maintain a constant duct static pressure. The refrigerant hot gas bypass uses hot gas from the discharge side of the compressor to falsely load the evaporator coil. This false loading prevents the low refrigerant operating pressures and accompanying problems mentioned previously.
Specifically, hot gas must enter the system between the expansion valve and the liquid distributor. With multi-circuit evaporator coils, hot gas need only be piped to one of the circuits when the solenoid valves operate together. The exception to this is if 100 percent of the compressor capacity is to be bypassed, then hot gas should be piped to each coil circuit.
When the number of coil circuits is reduced with load, hot gas is piped to the last active circuit. When this is done, the capacity of the last active circuit must at least equal the unloaded capacity of the compressor. The liquid distributor used must be of the low pressure drop, Venturi type. Orifice type distributors are not acceptable unless the bypass gas can be introduced after the orifice plate. The reason is that the orifice distributor is designed for liquid flow only and will not permit an adequate gas flow rate.
Since hot gas must enter between the expansion valve and distributor, multi-outlet expansion valves are not suitable. The hot gas bypass valve must be located close to the compressor, using as short a bypass valve-to-discharge line connection as possible and routed in a manner that will not allow oil trapping. Since the flow of bypassed gas is modulated, at times the velocity within risers will fall below that needed for oil entrainment. Therefore, when the evaporator is located above the compressor, a hot gas bypass-to-suction oil return line must be installed at the base of the riser. The bypass line is constructed from five feet of 1⁄8 inch tubing. This provides the pressure drop needed to prevent excessive short circuiting of hot gas to suction, yet the tube is large enough to drain the riser.
Further, the hot gas bypass of the prior art requires special modulating control valves as well as special refrigerant piping to be added to the rooftop unit. Adding hot gas bypass to a rooftop unit not only adds considerable first cost to the unit, but the false loading of the evaporator coil wastes energy. Hot gas bypass is complicated to install, complicated to commission, and should be serviced only by upper echelon air conditioning service technicians. The type of unit just described is an expensive special-purpose unit and is very different from the existing single-zone units that would be found on small offices, malls, and retail stores. It is safe to say that none of the thousands and thousands of rooftop single-zone units on small offices, malls, and retail stores have variable airflow capability nor do they have hot gas bypass. More to the point, retrofits for variable air flow and hot gas bypass are not used for the same reasons (expensive, complicated).
A major difference between previous air conditioning methodology and the present invention is the novel way in which the inherent problems of variable airflow with DX cooling coils are solved. This is a key difference that allows the present invention to be cost effective to buy and install, as well as energy efficient to run. Referring now to FIGS. 4 and 5, DX coils that have multiple compressors are generally circuited one of two ways, face split or interlaced. The direction of air flow is represented by arrow 20; the direction of flow of liquid refrigerant is represented by arrow 21; and the direction of refrigerant suction is represented by arrow 22.
In the present invention, automatic control dampers are added to prevent air bypass through the de-energized coil face at partial cooling loads. The damper is only closed during partial cooling loads in order to keep the air pressure drop through the cooling coil to a minimum. This minimization of the air pressure drop further reduces the fan energy usage. The fan speed is indexed to maintain the suction pressure of the energized coil (not the static pressure of the ducts, as in the prior art). The method used to control the suction pressure is to control the coil discharge air dewpoint temperature since there is a consistent relationship in a DX coil among leaving air temperature, leaving air dewpoint temperature, coil suction temperature, and coil suction pressure. Controlling the fan in this manner accomplishes the purpose of controlling suction pressure, but it also controls the occupied space to a maximum relative humidity level.
In contrast, the dehumidification methodology currently used in the HVAC industry employs a constant volume fan, cooling/dehumidification coil, and a reheat coil. The air is cooled/dehumidified to a prescribed dewpoint, then reheated as necessary to maintain the space temperature setpoint. This concept, while effective, wastes fan energy, compressor energy, and reheat energy.
The present invention accomplishes the same end result using only as much fan energy and compressor energy as necessary to achieve the maximum relative humidity setpoint. Reheat and the energy to produce reheat, are totally eliminated. The suction pressure control methodology herein described applies to both face-split and interlaced DX cooling coils, and is not currently employed in the air conditioning industry.
As noted previously, most HVAC units are oversized. The suction pressure control methodology of the present invention allows the fan speed to be reduced at full load as well as part load on most HVAC units. This results in additional fan and compressor energy savings while providing a lower space-relative humidity at full load. Whereas controlling the fan speed at part load saves on kilowatt hours consumed, controlling the fan speed at full load not only saves kilowatt hours consumed, but also reduces the kilowatt demand of the HVAC unit.
This is accomplished by setting the fan speed to maintain a certain coil discharge air dewpoint temperature and, accordingly, suction pressure. As the dewpoint drops, the fan speeds up, and conversely, as the dewpoint rises, the fan slows down. An example of the effect of enabling the present invention on reducing kilowatt demand of an HVAC unit at full load is the following: An HVAC unit computer selection program was used to model two sets of conditions. The first set of conditions modeled a standard HVAC unit on a design summer day without the present invention. The second set of conditions modeled the identical HVAC unit on the identical day with the present invention enabled. The chart below shows the conditions that were modeled:
EFFECT OF INVENTION ON kW DEMAND
Comparison Study














Unit With Present
Unit With Present



Invention Disabled
Invention Enabled


















Supply airflow cubic feet
6000 cfm
5000 cfm


per minute


Outside air airflow intake
600 cfm
500 cfm


cubic feet per minute


Sensible heat ratio of room
0.84
0.85


Outside air conditions
95° F. db/78° F. wb
95° F. db/78° F. wb


HVAC unit external static
.75 inches of water
.52 inches of water


pressure
column
column


Resultant room conditions
72° F./55% RH
72° F./50% RH


Evaporator coil leaving dry
52.4° F.
49.4° F.


bulb temp









Present Invention Enabled Vs Present Invention Disabled:

















Total HVAC unit capacity
−4.7%



Total compressor energy efficiency ration (EER)
−1.8%



Fan kW
−42.4%



Total HVAC unit EER
+3.8%



Total compressor kW
−3.0%



Total HVAC unit kW
−8.2%










Accordingly, the present invention lowers the HVAC unit airflow to achieve a lower leaving air dewpoint and thereby limit the relative humidity of the room. This additionally results in raising the overall efficiency (EER) of the HVAC unit while reducing the HVAC unit's total kilowatts (kW) used, thus substantially reducing the kW demand of the unit. The small drop in capacity is of little consequence as almost all single-zone units are oversized, as previously mentioned.
Regardless of the cooling coil circuiting, in either case, suction pressure will be maintained at acceptable levels without the use of the expensive first cost, energy inefficient, and difficult to service, hot gas bypass that was used in the prior art. The use of the present invention on face split coils is more expensive and costs more to install than for the interlaced coil, due to the need to furnish and install a face damper and damper operator. On the other hand, the face split version of the present invention will save more energy than the interlaced version because the fan speed can be reduced further at part loads. However, the magnitude of the overall first cost difference and operating cost difference of the two embodiments is very small.
Because the present invention is much less complex than hot gas bypass, any light commercial air conditioning technician can easily service it. The present invention is economically feasible, as compared to an installation of hot gas bypass retrofit, the high first cost, high installation cost, and limited energy savings of which would make such a product not economically justifiable.
Another difference between the present invention and the prior art is the novel demand ventilation feature that is built into the present invention. Today, indoor air quality is a significant health concern. As single-zone units historically have been low-cost, low feature products, the only way to address indoor air quality on these units has been a manual damper setting for the damper that controls the percentage of outdoor (ventilation) air that is allowed to be brought into the rooftop unit. If the damper setting allows too much outside air into the building to provide for adequate indoor air quality, the energy use of the unit is more than it needs to be. If the damper setting allows too little outside air into the building to provide adequate indoor air quality, the building is a candidate for what is now known as “Sick Building Syndrome.” With regard to the amount of ventilation air that is brought into a building, saving energy and improving indoor air quality are at cross purposes. Improving one sacrifices the other, so in order to save energy and still have acceptable indoor air quality, one should ventilate only as much as is necessary for acceptable indoor air quality, but no more than is necessary.
In addition to humidity measurement as reflected in the discharge air dewpoint temperature, there are two primary methods of measuring indoor air quality, carbon dioxide sensors (CO2), and volatile organic compound sensors (VOC). Since humans exhale CO2, measuring the CO2 levels in the space is a good indication of the people density and correspondingly, the indoor air quality. VOC sensors do not read CO2, but can measure “most anything that smells.” VOC sensors are better for measuring things such as off-gasses from new carpet and wallpaper, but there is not a finite way to quantify the measured values. As a result, CO2 sensors have become the most commonly used method of measuring indoor air quality. Although there are several methods of determining the proper indoor CO2 levels, a concentration of less than 1000 ppm (parts per million) is generally considered good indoor air quality.
Modulating the ventilation rate as required to maintain a maximum of 1000 ppm of CO2 is called demand ventilation. The present invention has demand ventilation built into it and allows the end user to select from three different ways to implement it. Two of the methods are well known to the air conditioning industry, the third is novel and unique to the present invention.
In all three cases, a CO2 sensor is installed either in the conditioned space or in the rooftop unit return air stream. The present invention allows the end user to set the maximum desired CO2 concentration level (generally 1000 ppm). Demand ventilation is achieved by adding one of the three options described below.
Option 1—
The present invention produces a variable 0-10 VDC output signal to modulate the outside (ventilation) air damper as required to keep the C02 concentration below set point.
Option 2—
The present invention produces a 0 or 24 VAC signal to either open or close a two-position outside air damper for as long a time period as is required in order to keep the CO2 concentration below set point.
Option 3—
Referring to FIG. 6, the outside air damper 13 is manually set to provide proper ventilation air at maximum occupancy and maximum airflow. At part load/reduced airflow conditions, which occur during 90% or more of the occupied hours, the outside air quantity will be reduced proportionally to the supply air volume.
At part load, the supply air volume is reduced to its normal level to match the cooling/heating/ventilation load. As long as the CO2 level is below set point, the fan speed is indexed to its normal value. If the CO2 level starts to approach the maximum CO2, the fan speed is modulated upward. As the supply fan 14 is modulated upward, the outside air (ventilation) quantity is proportionally increased, which will reduce the CO2 concentration. It is important to note that the fan speed is only increased above its normal speed as necessary to keep the CO2 value at or below set point. Since all three options may be used, the end user can decide which option fits the particular first cost and energy consumption situation the best.
Option 1 has the highest initial cost, but it is also the most energy efficient. It will normally require that additional control hardware be added to the unit. This is currently the method of choice in the air conditioning industry and is used on more complex and expensive air conditioning units.
Option 2 is a little less expensive than Option 1 since it could possibly utilize some of the existing hardware on the unit, although additional wiring would be required. Energy efficiency will be slightly less than Option 1, and there will be larger swings in the space CO2 levels since the control is on/off instead of modulating.
Option 3 is by far the least costly option of the three. There is no additional wiring or hardware as all of the central logic is built into the present invention. The accuracy of control is comparable to Option 1. Although this option is the least energy efficient of the three, the magnitude of that efficiency difference depends on the load profile of the area being served by the rooftop unit. Load profile takes into consideration the yearly outdoor weather, internal equipment and light loads, and most importantly, the occupancy density levels.
In small office buildings, the load profile is fairly consistent, except for the weather, but in shopping malls and retail stores, the largest variable is the people density. In those cases, the most likely factor to drive a rooftop unit to maximum cooling capacity is the people load, so in those cases, the energy downside of Option 3 is minimal at best because these buildings seldom reach maximum people density.
The reason Option 3 is an important part of the present invention retrofit is that it gives end users the opportunity to “get current” with the indoor air quality (IAQ) requirements with an affordable product. Having to add the complexity and cost inherent in Options 1 and 2 might prevent the end user from doing the retrofit at all. When energy and functionality are considered, on a scale of 1 to 10 with 10 being the best, Option 1 is a 10, Option 2 is a 9, and Option 3 is in the range of 7 to 10 depending on the load profile. When first cost and maintenance cost are considered, Option 1 is a 3, Option 2 is a 5, and Option 3 is a 10. The concept of Option 3 and the present invention retrofit in general matches with the concept of single-zone rooftop units in the first place, as lots of low-cost but functional rooftop units need lots of low-cost but effective retrofits.
Thus, again referring to FIG. 6, the present invention retrofit kit 10 consists of the following components:
1. Variable frequency drive controller 11;
2. Power wiring harness specifically designed for the forced air heating/cooling system's size, type, and manufacturer (not pictured);
3. Control wiring harness specifically designed for the forced air heating/cooling system's size, type, and manufacturer (not pictured);
4. Evaporator face damper 12 when required. Certain models of different brands of forced air heating/cooling systems may not require this damper. The physical size of the face damper varies depending on the exact manufacturer and model of the forced air heating/cooling system;
5. Face damper wiring harness specifically designed for the forced air heating/cooling system's size, type, and manufacturer (not pictured); and
6. A CO2 analog return sensor 15 in either the conditioned space or in the return air stream.
Hence, outside air enters through manual damper 13 and return air enters through the return air plenum 16. The CO2 return air sensor 15 evaluates the CO2 level in the return air and sends that information to modulating controller 11, which sets the supply fan 14's speed to pull more or less outside air in as required. Air flows through the system as usual past filter 17, condenser fans 18, and compressors 19. Control damper 12 acts as described above and air passes across the face split evaporator coil 20, exiting through supply air vent 21.
The benefits of varying the supply air volume during particular cooling loads include not only saving supply fan motor energy, but improving occupant comfort and indoor air quality. Compressor energy is also saved.
Additionally, a reduction of fan horsepower proportionally reduces the magnitude of the fan heat (kinetic energy) that is added to the air. The benefits of reduced fan heat are two-fold. First, less fan heat means less airflow to the conditioned spaces is required, which saves operating cost. Second, less fan heat reduces the required compressor load and saves operating cost.
Actual test data logged during summer operation from three 25 Ton single-zone units is shown below. The units were run with and without the present invention enabled. The total unit energy consumption was compared, and savings obtained by enabling the present invention averaged nearly 60%:













Present Invention Enabled















Savings


Present Invention Disabled



obtained















Total


Total


by



Kilowatt


Kilowatt


enabling


HVAC
Hours
Runtime
Kilowatts
hours
Runtime
Kilowatts
present


Unit
Consumed
Hours
per Hour
consumed
Hours
per Hour
invention

















SZ-1
11,332.8
576.53
19.66
6,230.8
600.27
10.38
47.2%


SZ-2
6,164.3
301.87
20.42
5,066.0
429.87
11.78
42.3%


SZ-2
6,172.1
331.21
18.64
5,384.0
1051.18
5.12
72.5%


Total
23,669.2
1209.61
19.57
16680.8
2081.32
8.01
59.1%









(average)









Referring now to FIG. 7, the energy saving potential of the present invention is further demonstrated. Assume a nominal 15 ton rooftop unit with dual compressors and a face-split evaporator coil; 4700 cfm maximum airflow; 20% outside air makeup; 95° F. dry bulb, 76° F. wet bulb outside design conditions; 72° F. dry bulb, 50% relative humidity indoor design conditions; indoor sensible heat ratio (SHR) of 0.95; and a total cooling capacity of 181,000 Btu/hr. At full cooling load coincident with indoor and outdoor design conditions, the mixed air temperature entering the cooling coil would be 76.6° F. dry bulb and 64.0° F. wet bulb. At a 0.95 SHR, the leaving evaporation temperature would be 51.0° F. dry bulb and 50.8° F. wet bulb.
Assume that at partial cooling load conditions, the outdoor temperature is 85° F. dry bulb and 76° F. wet bulb (a warm, muggy day), and also assume that the indoor conditions are such that one stage of cooling is on and one stage of cooling is off. The following is a comparison of a conventional rooftop heating/cooling system to a rooftop heating/cooling system having the present invention retrofit with one stage of cooling on.














Conventional System
Present Invention




















Supply Air cfm
4,700
cfm
2350
cfm


Outside Air Quantity
940
cfm
470
cfm


Outside Air Load (OA)
55,455
Btu/hr
27,728
Btu/hr


Fan Heat Load
11,946
Btu/hr
1,502
Btu/hr


Compressor KW for OA
4.25
KW
2.13
KW


Compressor KW for Fan Heat
.92
KW
.16
KW


Supply Fan KW
3.51
KW
.44
KW


Total Compressor and
8.68
K
2.73
KW


Supply Fan KW


Supply Fan Only
4.43
KW
.60
KW









Thus, when the effect of outside air on the entire A/C system is considered, the energy consumption due to outside air and fan heat of the present invention system is almost 70% less than the conventional system. Moreover, when only the supply fan saving is considered, the present invention reduces the additional energy consumption over 85%.
Airflow reduction has two positive effects on the airflow distribution system. First, airflow noise is reduced substantially when airflow is reduced, which is much less distracting to occupants. Second, occupant comfort is improved because drafts caused by high velocity discharge air are reduced. This is especially important in the heating and ventilating modes.
It is important to note that when the airflow is reduced, the air distribution throughout the system is proportional to the air distribution at maximum airflow. If the air distribution did not remain proportional at reduced airflow, hot spots and cold spots in the conditioned space could result and create occupant discomfort. To understand what is meant by the proportional air distribution, consider this example. If a diffuser in the system is delivering 12% of the total airflow at maximum total airflow, then it will still deliver 12% of the total airflow at 50% of total airflow. The reason the reduced airflow remains proportional is that reduced airflow effectively makes ductwork oversized, which is sometimes referred to in the HVAC industry as the “plenum effect.” To explain the “plenum effect” in a duct, consider the following:

    
    
        1. Total Pressure=Static Pressure+Velocity Pressure
        2. As the airflow is decreased, the total pressure is decreased.
        3. As the total pressure decreases, the static pressure percentage of the total pressure increases and the velocity pressure percentage of the total pressure decreases. If the fan continues to run, but the air is restricted to the point there is no flow (a condition called “Block Tight Static Pressure”), the velocity pressure is zero and therefore the total pressure equals the static pressure.
    
    


A field test was conducted to verify the above theory. A 100-foot long low velocity duct with ten outlets was selected for the test. The duct was designed at 0.08 inches of water column per 100 equivalent feet of duct using the equal friction duct design method. Thermal anemometers were used to read the airflow at each of the ten outlets. The thermal anemometers were calibrated using a calibrated airflow hood. The airflow at each outlet was logged starting with a fan motor running at 60 HZ or 100% airflow. The fan speed was then reduced by the controller of the present invention in approximately 10% increments down to 40% of total airflow. Finally, the airflow values were logged at each outlet each time the speed was reduced. Referring to FIGS. 8-12, the percentage of total airflow at each outlet was then plotted for each fan speed versus maximum airflow. Referring to FIG. 13, the results were then summarized.
The data showed that the percentage of airflow distributed to each outlet was essentially constant regardless of the airflow speed. Because the airflow distribution does remain proportional as the airflow speed is reduced, varying the airflow speed according to the present invention should not result in the creation of hot spots or cold spots, and the comfort levels should remain consistent with those at 100% airflow speed.
Uniquely, by setting the fan speed to maintain a certain suction pressure and thus coil discharge air dewpoint temperature, the present invention takes into account the evaporator refrigerant coil circuiting to insure that the evaporator leaving air conditions are consistent at all stages of cooling. Conventional rooftop air conditioning units have elevated evaporator leaving air temperature at partial cooling load, which causes the relative humidity of the space served by the unit to become elevated. This rise in relative humidity causes several problems, including discomfort of the people occupying the space and potential indoor air quality problems in the form of mold and mildew.
By contrast, the present invention maintains the relative humidity of the space at a lower level, and thus the evaporation rate of the perspiration on the skin of the occupants in the space increases. This increased evaporation rate allows the temperature set point of the space to be raised but still maintain a consistent level of comfort. A 10% reduction in relative humidity allows the room temperature set point to be raised one degree F. and achieves the same comfort conditions. Raising the set point results in compressor energy savings. Moreover, the potential for mold and mildew growth, which generally occurs above 60% relative humidity, is essentially eliminated. Thus, in addition to dramatically reducing the energy consumption at part load, the present invention will beneficially reduce the relative humidity of the space being served by as much as 20% depending on the volume of outside air and outdoor air temperature and humidity conditions.
In cases where there is a high density of people in the space and this density is variable, the present invention permits the outside air ventilation to vary in proportion to the supply air quantity. This allows additional significant compressor operating cost savings at partial cooling load, as well as reduced relative humidity in the space in the dead band and heating modes.
Because the present invention causes the evaporator fan and fan motor to operate at reduced speeds for extended periods of time, the fan belt life, fan bearing life, and motor bearing life are almost doubled. Further, the frequency of lubricating these bearings and changing or tightening the belts can be reduced by almost half, which saves replacement bearings, belts, and associated maintenance costs. In addition, due to the incremental nature of change in fan speed desired (as opposed to simply “full on” or “full off”), an inherent characteristic of the present invention is that when it starts the supply fan, it slowly ramps up the speed of the motor (soft start) as opposed to taking the motor from “OFF” to full speed instantly. The instantaneous starting of a motor requires the motor to produce significant starting torque. This starting torque shortens the life of the fan and motor bearings and especially shortens the life of the fan belt. Soft starting greatly reduces the starting torque and extends the life of all of these components.
Additional benefits afforded by the present invention's reduced airflow include both maintenance cost benefits and improved indoor air quality. These benefits are derived from the reduced airflow for extended periods of time across the forced air heating/cooling system filters. When less air is being moved, the filter life is extended, which saves maintenance costs. Additionally, reducing the airflow across the filters increases the filtration efficiency of the filters, further improving the indoor air quality of the conditioned space served by the forced air heating/cooling system.
The operation of the control systems to vary the speed of a fan motor for a forced air heating/air system for the advantageous purposes set forth herein is believed to be understandable to those of ordinary skill in the art based on the foregoing description. Wiring diagrams for use with an existing thermostat or control system and for use with a room temperature and optional relative humidity sensor, respectively, are presented in FIGS. 14 and 15. Both versions are Native BACnet protocol and may be accessed by any BACnet based building automation system.
The benefits of the instant invention over the prior art are many, and include the following: (1) reduced supply fan energy consumed during a high percentage of operating hours; (2) reduced compressor energy consumed by reducing fan heat; (3) reduced compressor energy consumed by reducing outside air load; (4) reduced relative humidity at partial loads which increases comfort and reduces chance of mold and mildew growth; (5) reduced heating energy consumed by reducing outside air load; (6) lower airflow sound levels at partial loads; (7) reduced maintenance cost by reducing the preventative maintenance of fans, motors, and filters; (8) increased component life of supply fan motor bearings, fan hearings, and fan belts; (9) improved indoor air quality by lowering relative humidity and improving filtration; (10) increased comfort for occupants by reducing drafts in ventilation and heating modes; and (11) ability to control CO2 levels in the space.
Installing the present invention retrofit on an existing HVAC unit will extend the life of the unit by adding protections not found in any but the most current single-zone new HVAC units. If the evaporator fan variable frequency drive shuts down on a fault, the present invention shuts down all cooling and heating functions. As a result, the entire HVAC unit gets the following additional protections:
1. phase failure;
2. phase reversal;
3. evaporator fan motor failure;
4. belt breakage detection;
5. motor and drive overload;
6. motor and drive under voltage; and
7. ground fault protection.
The present invention also contains an HVAC unit diagnostic tool and has alarm notification built in to provide the user with instantaneous fan fault notification, as well as proactive alarms to notify the user if the HVAC unit is not operating properly even though the unit may still be running. This notification may be provided by three methods. The first method is a blinking red light on the present invention itself. The number of times the light blinks in succession alerts the user to the particular alarm. The second method provides a contact closure that may be connected to any building automation or alarm system to notify the user of an alarm. The third method is an open protocol Native BACnet interface port. BACnet is the open protocol developed by the American Society of Heating, Refrigeration, and Air Conditioning Engineers. BACnet is one of two premiere open protocols used today in the air conditioning industry worldwide. BACnet provides the user the following description of the alarm:

    
    
        Alarm 1 Variable frequency drive (VFD) fault
        Alarm 2 Block-off damper failed to open (face split coils only)
        Alarm 3 Refrigerant suction pressure too low Circuit 1
        Alarm 4 Refrigerant suction pressure too low Circuit 2
        Alarm 5 High discharge air temperature during cooling
        Alarm 6 Refrigerant head pressure too high Circuit 1 (Version II only)
        Alarm 7 Refrigerant head pressure too high Circuit 2 (Version II only)
        Alarm 8 Compressor 1 failed to start
        Alarm 9 Compressor 2 failed to start
        Alarm 10 Supply air temperature sensor has failed

Thus, Alarm 1 shuts down all HVAC unit functions to protect the unit components; alarms 2-9 provide a proactive warning to the user that the HVAC is not operating properly; and alarm 10 alerts the user to an operational problem and also reverts to normal operation and disables operation until the sensor is repaired.

    
    


Moreover, the present invention is the only single-zone rooftop retrofit design that provides (1) variable airflow in the cooling mode as well as heating and ventilation modes and (2) demand ventilation control. Further, the present invention employs variable airflow control for face split DX coils using face dampers; variable airflow control for interlaced DX coils using suction pressure/variable airflow control; and demand ventilation control utilizing variable supply fan airflow. Although preferred embodiments of the invention have been described in detail herein, those skilled in the art will also recognize that various substitutions and modifications may be made without departing from the scope and spirit of the appended claims.

## Claims

1. A retrofit control system for controlling the speed of a fan motor for a forced air flow air conditioning system operable in heating, ventilation, deadband, and part load cooling modes to control supply air speed during operation of said air conditioning system to reduce energy consumption, and provide humidity and CO2 air quality control, said control system comprising:
(a) a suction pressure sensor located on a suction refrigerant line exiting a direct expansion cooling coil;
(b) a control mode input relay digital input circuit;
(c) a power output circuit for controlling the speed of said fan motor in accordance with a control mode input signal;
(d) a CO2 analog sensor in either the conditioned space or in the return air stream;
(e) a heating operation and cooling operation selection circuit operably connected to said power output circuit and input relay circuit and suction pressure sensor for varying the air flow in each of the cooling, heating, ventilation and deadband modes, controlling refrigerant suction pressure, and modulating the ventilation rate as required to maintain a maximum of 1000 ppm of CO2 and a preset coil discharge air dewpoint temperature.

2. The control system of claim 1, wherein said control system is preprogrammed to match a specific brand and model of air conditioning system based on the cooling and heating capacity of said system.

3. The control system of claim 1, wherein the heating operation and cooling operation selection circuit produces a variable 0-10 VDC output signal to modulate the ventilation air damper as required to keep the CO2 concentration as measured by a CO2 monitor below set point.

4. The control system of claim 1, wherein the heating operation and cooling operation selection circuit produces a 0 or 24 VAC signal to either open or close a two-position outside air damper for as long a time period as required to keep the CO2 concentration as measured by a CO2 monitor below set point.

5. The control system of claim 1, wherein the outside air damper is manually set to provide proper ventilation air at maximum occupancy and maximum air flow and modulates the supply fan speed as required to keep the CO2 concentration, as measured by a CO2 monitor, below set point.

6. The control system of claim 1, wherein the speed of the supply fan is slowly accelerated.

7. The control system of claim 1, wherein the system controls the speed of a fan motor for a forced air flow air conditioning system for a space wherein fan speed is indexed to maintain a preset maximum relative humidity level in the space.

8. The control system of claim 1, wherein the system controls the speed of a fan motor for a forced air flow air conditioning system for space wherein fan speed is controlled to vary air flow in heating, ventilation, deadband, and part load cooling modes such that energy consumption is reduced.

9. The control system of claim 1, wherein the system controls the speed of a fan motor for a forced air flow air conditioning system for a space wherein fan speed is indexed to maintain a preset maximum CO2 level in the space such that CO2 air quality is maintained at a preset maximum value of CO2 concentration.

10. The control system of claim 1, wherein the system controls the speed of a fan motor for a forced air flow air conditioning system for space wherein fan speed is modulated to maintain a preset maximum relative humidity level in the space such that energy consumption is reduced and maximum CO2 levels and relative humidity are maintained.

11. The control system of claim 10, wherein:
(a) a suction pressure sensor analog input circuit is located on a suction refrigerant line exiting a direct expansion cooling coil;
(b) a control mode input relay digital input circuit produces a signal based on the suction pressure data;
(c) a power output circuit produces a signal and controls the speed of said motor as a function of said output signal to vary the speed of said motor in accordance with said control mode input signal;
(d) a CO2 analog sensor in either the conditioned space or in the return air stream senses the CO2 levels in the space on air stream; and
(e) a cooling operation selection circuit is operably connected to said power output circuit, said input relay circuit, and said suction pressure sensor for varying the air flow in each of the cooling, ventilation and deadband modes, and modulating the ventilation rate as required to maintain a preset maximum level of CO2 and a set coil discharge air dewpoint temperature; and
(f) an evaporator face damper on the de-energized coil section prevents air bypass through the de-energized coil face at partial cooling loads.

12. The control system of claim 11, wherein said control system is preprogrammed to match a specific brand and model of air conditioning system based on the cooling and heating capacity of said air conditioning system.

13. The control system of claim 11, wherein the heating operation and cooling operation selection circuit produces a variable 0-10 VDC output signal to modulate the ventilation air damper as required to keep the CO2 concentration as measured by a CO2 monitor below set point.

14. The control system of claim 11, wherein the heating operation and cooling operation selection circuit produces a 0 or 24 VAC signal to either open or close a two-position outside air damper for as long a time period as required to keep the CO2 concentration as measured by a CO2 monitor below set point.

15. The control system of claim 11, wherein the outside air damper is manually set to provide proper ventilation air at maximum occupancy and maximum air flow and modulates the supply fan speed as required to keep the CO2 concentration, as measured by a CO2 monitor, below set point.

16. The control system of claim 11, wherein the speed of the supply fan is slowly accelerated.

17. The control system of claim 1, wherein the system controls the speed of a fan motor for a forced air flow air conditioning system operable in ventilation, deadband, and part load cooling modes, respectively, to control supply air fan speed during operation of said air conditioning system, by:
(a) sensing suction pressure on a suction refrigerant line exiting a direct expansion cooling coil;
(b) inputting said pressure data into a control mode input relay digital input circuit;
(c) controlling the speed of said motor through a power output circuit to vary the speed of said motor in accordance with a control mode input signal;
(d) employing a CO2 analog sensor in either the conditioned space or in the return air stream; and
(e) employing a cooling operation selection circuit operably connected to said power output circuit, said input relay circuit, and said suction pressure sensor for varying the air flow in each of the cooling, ventilation, and deadband modes, controlling refrigerant suction pressure, and modulating the ventilation rate, as required to maintain a maximum set concentration of CO2 and a set coil discharge air dewpoint temperature.

18. The control system of claim 17, wherein the cooling operation selection circuit produces a variable 0-10 VDC output signal to modulate the ventilation air damper as required to keep the CO2 concentration, as measured by a CO2 monitor, below set point.

19. The control system of claim 17, wherein the cooling operation selection circuit produces a 0 or 24 VAC signal to either open or close a two-portion outside air damper for as long a time period as required to keep the CO2 concentration, as measured by a CO2 monitor, below set point.

20. The control system of claim 17, wherein the outside air damper is manually set to provide proper ventilation air at maximum occupancy and maximum air flow and modulates the supply fan speed as required to keep the CO2 concentration, as measured by a CO2 monitor, below set point.

21. The control system of claim 17, wherein the speed of the supply fan is slowly accelerated.

22. The control system of claim 1, wherein the system controls the speed of a fan motor for a forced air flow air conditioning system operable in heating, ventilation, deadband, and part load cooling modes to control supply air speed during operation of said air conditioning system to reduce energy consumption, and provide humidity and CO2 air quality control, said control system comprising:
(a) a suction pressure sensor located on a suction refrigerant line exiting a direct expansion cooling coil;
(b) a control mode input relay digital input circuit;
(c) a power output circuit for controlling the speed of said fan motor in accordance with a control mode input signal;
(d) a CO2 analog sensor in either the conditioned space or in the return air stream;
(e) a heating operation and cooling operation selection circuit operably connected to said power output circuit and input relay circuit and suction pressure/temperature sensor for varying the air flow in each of the cooling, heating, ventilation and deadband modes, controlling refrigerant suction pressure, and modulating the ventilation rate as required to maintain a maximum of 1000 ppm of CO2 and a preset coil discharge air dewpoint temperature; and
(f) preprogramming to match the retrofit control system with a specific brand and model of air conditioning system based on the cooling and heating capability of said system;
wherein said heating operation and cooling operation selection circuit produces a variable 0-10 VDC output signal to modulate the ventilation air damper as required to keep the CO2 concentration as measured by a CO2 monitor below set point, and the speed of the supply fan is slowly accelerated.

23. The control system of claim 1, wherein the system controls the speed of a fan motor for a forced air flow air conditioning system operable in heating, ventilation, deadband, and part load cooling modes to control supply air speed during operation of said air conditioning system to reduce energy consumption, and provide humidity and CO2 air quality control, said control system comprising:
(a) a suction pressure sensor located on a suction refrigerant line exiting a direct expansion cooling coil;
(b) a control mode input relay digital input circuit;
(c) a power output circuit for controlling the speed of said fan motor in accordance with a control mode input signal;
(d) a CO2 analog sensor in either the conditioned space or in the return air stream;
(e) a heating operation and cooling operation selection circuit operably connected to said power output circuit and input relay circuit and suction pressure sensor for varying the air flow in each of the cooling, heating, ventilation and deadband modes, controlling refrigerant suction pressure, and modulating the ventilation rate as required to maintain a maximum of 1000 ppm of CO2 and a preset coil discharge air dewpoint temperature; and
(f) preprogramming to match the retrofit control system with a specific brand and model of air conditioning system based on the cooling and heating capacity of said system;

wherein the outside air damper is manually set to provide proper ventilation air at maximum occupancy and maximum air flow and modulates the supply fan speed as required to keep the CO2 concentration, as measured by a CO2 monitor, below set point, and the speed of the supply fan is slowly accelerated.

24. A method of controlling the speed of a fan motor for a forced air flow air conditioning system operable in heating, ventilation, deadband, and part load cooling modes, respectively, to control supply air fan speed during operation of said air conditioning system to reduce energy consumption, and provide humidity and CO2 air quality control, said method comprising:
(a) employing a suction pressure sensor analog input circuit located on a suction refrigerant line exiting a direct expansion cooling coil;
(b) employing a control mode input relay digital input circuit;
(c) employing a power output circuit for controlling the speed of said motor as a function of said output signal to vary the speed of said motor in accordance with a control mode input signal;
(d) employing a CO2 analog sensor in either the conditioned space or in the return air stream; and
(e) employing a heating operation and cooling operation selection circuit operably connected to said power output circuit and said input relay circuit and suction pressure sensor for varying the air flow in each of the cooling, heating, ventilation and deadband modes, controlling refrigerant suction pressure, and modulating the ventilation rate as required to maintain a maximum of 1000 ppm of CO2 and a set coil discharge air dewpoint temperature.

25. The method of claim 24, wherein the heating operation and cooling operation selection circuit produces a variable 0-10 VDC output signal to modulate the ventilation air damper as required to keep the CO2 concentration, as measured by a CO2 Monitor, below set point.

26. The method of claim 24, wherein the heating operation and cooling operation selection circuit produces a 0 or 24 VAC signal to either open or close a two-portion outside air damper for as long a time period as required to keep the CO2 concentration, as measured by a CO2 monitor, below set point.

27. The method of claim 24, wherein the outside air damper is manually set to provide proper ventilation air at maximum occupancy and maximum air flow and modulates the supply fan speed as required to keep the CO2 concentration, as measured by a CO2 monitor, below set point.

28. The method of claim 24, wherein the speed of the supply fan is slowly accelerated.